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Development and operation of a closed industrial waste water system

page 001

Development and Operation of a Closed
Industrial Waste Water System
DONALD I. ANGELBECK, Senior Environmental Specialist
WALTER B. REED, Process & Quality Control Manager
Barrington Plant
SAMUEL H. THOMAS, Director of Environmental Control
Owens-Corning Fiberglas Corporation
Granville, Ohio
INTRODUCTION
The development of the manufacture of glass fibers for use in commercial
insulation began in 1931. An important part of this development was the
advancement of an economical chemical system which provided fiber to fiber
bonding. Throughout the years a basic phenol-formaldehyde resin bonding system
has remained as a standard throughout the industry. Unique problems associated
with the treatment, disposal and/or reuse of waste water containing phenolic resins
have existed. Unfortunately, little or no published information existed which
documented similar problems and their solution. The intent of this paper is to
summarize developments toward the successful operation of a closed industrial waste
water recycle system which provides a total solution to waste water problems
associated with the manufacture of glass fiber insulation.
PROCESS DESCRIPTION
The basic process for the production of glass fiber insulation is illustrated in
Figure 1. Raw materials such as silica, limestone, borates and etc. are mixed and fed
into a melting furnace. Molten glass flows into a fiberizer where the glass is spun and
attenuated into a mass of discontinuous fibers. The fiberous mass is directed
downward where binder, a dilute solution of resin and other chemicals, is sprayed
into the mass of attenuated fibers. The binder accumulates on each fiber surface. The
fiberous mass continues downward to a conveyer screen and forms a "wool-like"
pack. The pack undergoes curring in ovens where the phenolic binder is heat cured to
form a rigid material that bonds one fiber to another within the pack. The cured
pack is air cooled, cut, trimmed and packaged. The entire process is continuous It is
common for a single machine to have glass fiberizing rates of 8,000 to 14,000 pounds
of glass per hour and conveyer speeds of 50 to 200 lineal feet per minute.
When production changes are incurred, the molten glass flow is diverted from
the fiberizers and quenched with water. The glass immediately solidifies and fractures
into fragments resembling a mixture of sand and aggregate, which is termed glass
cullet. A major portion of the cullet is collected at the machine in hoppers for reuse
into the melting furnace.

Development and Operation of a Closed
Industrial Waste Water System
DONALD I. ANGELBECK, Senior Environmental Specialist
WALTER B. REED, Process & Quality Control Manager
Barrington Plant
SAMUEL H. THOMAS, Director of Environmental Control
Owens-Corning Fiberglas Corporation
Granville, Ohio
INTRODUCTION
The development of the manufacture of glass fibers for use in commercial
insulation began in 1931. An important part of this development was the
advancement of an economical chemical system which provided fiber to fiber
bonding. Throughout the years a basic phenol-formaldehyde resin bonding system
has remained as a standard throughout the industry. Unique problems associated
with the treatment, disposal and/or reuse of waste water containing phenolic resins
have existed. Unfortunately, little or no published information existed which
documented similar problems and their solution. The intent of this paper is to
summarize developments toward the successful operation of a closed industrial waste
water recycle system which provides a total solution to waste water problems
associated with the manufacture of glass fiber insulation.
PROCESS DESCRIPTION
The basic process for the production of glass fiber insulation is illustrated in
Figure 1. Raw materials such as silica, limestone, borates and etc. are mixed and fed
into a melting furnace. Molten glass flows into a fiberizer where the glass is spun and
attenuated into a mass of discontinuous fibers. The fiberous mass is directed
downward where binder, a dilute solution of resin and other chemicals, is sprayed
into the mass of attenuated fibers. The binder accumulates on each fiber surface. The
fiberous mass continues downward to a conveyer screen and forms a "wool-like"
pack. The pack undergoes curring in ovens where the phenolic binder is heat cured to
form a rigid material that bonds one fiber to another within the pack. The cured
pack is air cooled, cut, trimmed and packaged. The entire process is continuous It is
common for a single machine to have glass fiberizing rates of 8,000 to 14,000 pounds
of glass per hour and conveyer speeds of 50 to 200 lineal feet per minute.
When production changes are incurred, the molten glass flow is diverted from
the fiberizers and quenched with water. The glass immediately solidifies and fractures
into fragments resembling a mixture of sand and aggregate, which is termed glass
cullet. A major portion of the cullet is collected at the machine in hoppers for reuse
into the melting furnace.